Alfa Romeo Forums banner

21 - 40 of 66 Posts

·
Registered
Joined
·
4,090 Posts
WHERE THERE IS A WILL THERE IS A WAY !!!

Congrats!

Jes
 

·
Registered
Joined
·
18 Posts
Discussion Starter #23
Sorry the sound isn't great on the clip, but I'm sure all
of you know how good these engines sound allready,
hope to get a better quality clip up when we take her
out for the first test run.
 

·
Registered
Joined
·
4,501 Posts
Priceless - somebody should go and post that on the BMW forums... :)
 

·
Registered
Joined
·
3,771 Posts
The exhaust valves are pretty easy to adjust. I think that might make the ticking go away.

My E30 autoX buddy is going to love this...thank you for giving us some ammunition.
 

·
Registered
Joined
·
659 Posts
Geez you never get sick of hearing that sound, and I drive mine day in, day out! :D

For the record though, that sensor on the block next to the dipstick was actually the oil level sensor ;)

ROCK ON
R~R
 

·
Registered
Joined
·
18 Posts
Discussion Starter #28
Evenin all,
been a while since the last post as there hasn't been much engine work
in the last few weeks. After getting the engine running and checking over
the driveline we had to complete pre-paint assembly (cause having to
bash things with hammers in a freshly paint shell is a nervous task).
Once we got the dash cut and in around the cage we fitted the seat
runners, seats and harnesses..................



filled in the panel gaps we cut to run the cage to the rear turrets..........



welded up the eye bolts for the harneses............



then stuck a few panels on so we could take a quick test drive
without drawing to much attention (bit in vain really, the sideways driving
style and smoke from the rear tyres had just the same effect ) :eek::



the one thing both of us agreed upon after the test drive was that
while the engine noise was sweet the exhaust was far to quiet. We were
originally concerned that the car had to pass noise tests at track days
and had left the original 318 back box fitted, this had to go. A quick scan
around e-bay offered up a stainless renault 5 gt turbo back box for
35euro, 3 inch tail pipe, bingo..........





the neighbours now know in advance when this cars coming out
of the garage :D
Next up was to sort the new dash and switch pannel,
dash out and gutted............



this months subversive product advertisment.............



m.d.f. wood dash panel to offset the "carbon foot print"for any
tree huggers out there .............





centre switch panel along the same lines but out of perspex...........



cover it and fit the switches...............



and fit them both back in..............



then pull it all back assunder again and sand every nook and crany till
your fingers bleed. A quick trip to the scrap yard turned up some side
skirts and a front chin spoiler, as is par for the course now neither came
off a bmw :roll:



with the car now up the country in the bigger garage we could hang the
panels, place the car and errect the "Spray Boot 3000" (* patent pending)







hope to get the paint on this weekend.

The other thing we got around to with the engine back out for the final
time was my favorite job, engine bling time...............















and thats about it for now.
 

·
Registered
Joined
·
18 Posts
Discussion Starter #30
Thanks,
wire brushed the covers then filed the raised sections (the ridge lines, not the lettering) until they were flat, then sanded them with progressively finer grades of sandpaper up to 1500grit, which gave a polished finish. Steam clean to remove aluminium dust, then washed with standard thinners to remove all traces of oil, then sprayed with 2 coats of primer and 2 coats of red. Then used a flat bladed scalpel to etch paint from raised section followed by a quick 1500grit sanding to the raised section again to polish it up.
 

·
Registered
Joined
·
18 Posts
Discussion Starter #33
(not sure if this is the proper place for this being a bmw
on an Alfa site, so if it's not welcome please say)

Made some more progress again since last post.
First up was to get some paint on the car and after
sanding for what felt like forever it was finally time
to tape up and get some colours on. After painting
the car in primer and sanding it all again :cry: we
taped off the outside so we could first spray the interior
and engine bay white.................










with this done we could now refit the doors and bonnet and
tape up for the stripes, starting with the red ..............





and so on and on for the blue, purple and finally the white.................





then the nervous wait to see if the shinny paint would reveal
any distorsions to the roof skin after welding in the sunroof
pannel.............



thankfully there were no suprises.
So after leaving the paint to harden for a few days and making sure
all the flies that wanted to, had sufficient time to merge with the new
paint work (b**tards, i swear to god if ever anybody wants to study
wildlife just spray something and stand back and wait for it to dry,
we reckon if we sprayed a car in Africa there'd be a bloody elephant
stuck to it the next day!) Anyway wildlife aside, paint dry, time for
poly windows and door cards................







with the pedal box and other bits and pieces now refitted to the
engine bay it was time to fill the empty hole...............







nice what a lick of paint does isn't it...............






with the engine refitted it was time to start refitting all the other bits
and pieces, starting with the cold start valve we had decided to move
to clean up the rocker cover. The old position had the valve on top of
the rocker cover with pipes running all around it...................



so a bit of plumbing now allows it to reside at the rear of the
head................



next up is to make some holders to route the H.T. leads out from
the distributor cap, one done one to go.......................



and thats about where we are for now.
 

·
Registered
Joined
·
2,356 Posts
if you can get me some realy high detail shots of your re-route of the vac lines to "clean" up everything that would be GREAT...my 58 project will be greatfull
 

·
Registered
Joined
·
625 Posts
The car looks like a real beast, I am glad you kept it [mostly] white.
 

·
Registered
Joined
·
3,506 Posts
Are those exhaust headers too small for high RPM flow? I can't see the interior of my stock Alfa exhaust manifold pieces, but my eye tells me that the pipes in your exhaust header are smaller than I expect. Such a thing could limit your high-end power.

Michael
 

·
Registered
Joined
·
18 Posts
Discussion Starter #37
if you can get me some realy high detail shots of your re-route of the vac lines to "clean" up everything that would be GREAT...my 58 project will be greatfull
No problem, if you pm me your e-mail address I will
take some and send them on.
 

·
Registered
Joined
·
4,501 Posts
Nice job - really LOVE the detail and the clean engine-bay...!
 

·
Registered
Joined
·
18 Posts
Discussion Starter #40 (Edited)
Been a while since my last confession, we managed to get a
good bit more done so deep breath and heres the results of this
months efforts.

new rad arrived, looks sweet and more to the point weighs about
half as much as the old one, can only guess at how much crap was
set inside the old one..............





next up was to try and sort out the breather pipe that came out the top
of the rocker cover. This used to have a big ignorant looking breather
sitting on top of the rocker cover out of which ran another pipe that
recirculated the oily fumes back into the intake. We're trying to keep the
top of the engine as clean looking as possible, so we found a fitting that
could be "persuaded" (fancy word for hammered) into the rocker cover,
to which we could attach a pipe to and run it into a catch tank which we
have yet to fabricate..................





next up was the ht lead holders. We'd started to make one of these
in the last update but neither of us were mad gone on it, so as luck would
have it we spotted some nice aluminium strips in the local hard ware store
that looked as if they'd suit the leads size perfect...............







next up was to build a cold air feed duct which would replace one
of the e30's inner headlights. Not sure if this makes a blind bit of
difference to engine performance, but what it does do is lets more of
the induction noise out and thats worth any amount of effort in our
book. So, one rather large exhaust trumpet................



2 alum disc's cut to slide over it.....................



attach disc's to each other......................



spray them black and attach them to the trumpet................



remove headlight and replace with object................





next up the suspension kit had arrived from ze fatherland..............



brakes are staying standard all around for the mo, so all the original
running gear striped out and anything that was going back on got
striped, cleaned, overhauled and painted...................



reassembled with mintex pads, new wheels bearings, wishbones,
and m3 poly bushes. Still waiting on the braided brake pipes...............





rear suspension was along the same lines. Top shock mounts well
well past their sell by date, with the centers having burst out of them so
new mounts..................



rear axle out and polybush everything that looks like it moves...........



and bang it all back in with the new adjustable coils and shocks...........



next up was the little heat shields which protect the rubber engine
mounts from the heat of the exhaust, a manifold each side would require
a heat shield each side....................





the next thing we wanted to do was to wrap the manifolds to try
and keep the under bonnet temps down a bit so, 12 meters of fiber glass
wrap, 20 feet of lacing wire, 2 itchy and shredded hands and a bucket full
of patience.....................







it was actually unfortunate that we used up all our patience wrapping
the manifolds as we could have done with some more to cope with
the discovery that was made upon refitting the manifolds.
You might remember from earlier that the distance between the steering
coloum and the exhaust manifold was similar to the distance between a
snakes balls and the ground ie. tight. So it probably should have come
as no surprise that with the wrapping on the manifold this had now
become an interference fit.................



no matter how gifted you are at drifting a car and steering from the
rear, I've yet to meet someone who can do it without the use of the
steering wheel, so it was clear something was going to have to be sorted.
With hands still recovering from wrapping the manifolds the idea of
stripping it all off and altering the manifold was discounted very quickly.
Only one other option then really, move the bloody steering coloum.
With the coloum out we could see how much room there was to work
with.....................



you can see from above the size of the hole that the coloum protrudes
through the bulkhead from the white paint. The plan was to remake this
to move the coloum a half inch to the left in the picture, which we
calculated (guessed) would give us back good clearance at the manifold.
Strip the bracket from the coloum................



copy and make a new plate, and bolt it up to the bulkhead.............



mark the shape of the bulkhead hole on the far side of the
plate...........



very carefully mark where the tubing is going to weld to the new
plate, taking great care not to make a carbon copy of the plate you are throwing away, :mad: .....................



weld it all up, reassemble it and refit it and say a little prayer that
you haven't f**ked it up...................



in the voice of the great man himself, C. Montgomery Burns



next up was the black art of wiring up a car and the voodo thats
required to keep the smoke from escaping from inside the wires.
Main engine loom was laid in and just needed securing
and p cliping where possible................



there wasn't a great deal of slack left on the engine management
loom when it reappeared inside the cabin, so the 2 ecu's were going to
have to be mounted close by. First small one was straight forward
enough..................



the second larger one was going to take a bit more creativity. So a
bracket was fabricated..................





painted black and some foam tape applied to the inside ..............



a few rivet nuts fitted to the bulkhead................



and bang it up....................



next up was to fit the extra sensors the new dash display would
need. First up was the coolant temp. sensor. A quick study of the
thermostat housing showed up 3 sensors of which only 2 were going to
be used the 3rd one on the right was for the original temp gauge on the
old dash................



So just a simple job on removing one sensor and replacing it with
the other, untill we hit a small snag...........



the original was an m18 thread the new one an m10, we briefly
toyed with the idea of a couple of hundred wraps of thread tape 8O
before going searching for an adapter. We managed to find a fitting
with the correct outside thread but the inside was still a little to big at
11mm to take a taping out to m10. So we done more digging an got
a heli-coil to get the inside diameter down to m10..............



oil temp sender proved to be just as straight forward ie. pain in the
arse. We had overlooked (forgotten) in the inital building and painting
of the sump that a threaded boss would be required in the side of it. But
luckly we did remember it before we had fitted the engine back in for
the final time. Still meant removing the sump, drilling the hole and
welding the nut on before repainting the whole thing again and making a
new gasket. Still it would have been a bit worse I suppose if wee had to
pull the whole engine out again to do this, be greatfull for small mercies
and all that. (greatfull my arse, I hate making cork gaskets, twice)



next up was the fuse board. Usually this would be in a panel where
the heater controls used to be, but in this car the heater was being kept
so we had to find some where else for them. We decided upon a position
where the centre console used to be as it would also help secure the
bottom of the dash...............



fuse holder blocks from the motor factor, relay holders from a nissan
in the scrap yard......................







forgot to take a picture of it fitted it would appear, but you can see
it in the bottom right of the next pic, will look better when its finished and
covered (i hope)
next up was the indicator stalk. For a while now we've being using
a ford escort stalk :eek: in most of our builds simply because they're so
compact. They house the wiper controls, lights, indicators, and hazard
switch and relay all in the one stalk which cuts down on the amount of
different places you have to run wires to. First up was to remove the
old ignition barrel from the bm steering coloum, and then start fitting
the escort stalk in it's place. Then fabricate a clamp...............



weld an m6 nut to the top of the clamp...................



bolt stalk to clamp.................



fit object to coloum..............



with most of the major electrical items now fitted we could start
measuring up and laying in the new looms which is where we are at the moment ..................









On the bright side though we have reached the stage where the
amount of things left to be done now fits on a couple of fools cap pages

the end is nigh! :D
 
21 - 40 of 66 Posts
Top